Method for forming a cushion

Abstract

A seat cushion mold with an elastic member and method provide the manufacture of an improved seat cushion for use in upholstered chairs or the like having a smooth, uniform shape without unsightly underlines. A thick, resilient foam block is positioned on a rigid planer base and is urged into the mold whereby a thin foam cover layer is adhered to the outer edges of the planar base to produce a precisely contoured cushion which can be upholstered and fitted to a chair frame.

I claim: 
     
       1. A method for forming a cushion having a smooth bottom surface using a mold having an elastic member, wherein the elastic member is capable of being deflected to various depths as needed to properly form the cushion, said method performed in the absence of a vacuum, said method comprising the steps of: a) placing at least one resilient block on the top surface of a flat rigid planar base having side edges;   b) positioning a cover atop said resilient block, said cover layer having a width greater than the width of said planar base;   c) placing said cover layer, said resilient block, and said planar base onto said elastic member so that the bottom surface of said planar base is exposed;   d) initially pressing said bottom surface of said planar base to force said cover layer, said resilient block, and said planar base into said elastic member to an initial desired depth, while maintaining a perimeter of said planar base exposed;   e) deflecting said elastic member to thereby mold said cover layer and said resilient block;   f) forcing said cover layer against the side edges of said planar base as said cover layer is pressed further into said elastic member by pressing the bottom surface of said planar base to a sufficient depth within the mold; and   g) attaching said cover layer to the side edge of said planar base with excess cover layer extending beyond the bottom surface of said planar base to form a seat cushion.   
     
     
       2. The method of claim 1 wherein attaching said cover layer comprises the step of attaching said cover layer with an adhesive to said planar base. 
     
     
       3. The method of claim 1 wherein pressing upon the bottom surface of said planar base comprises the step of applying downward force upon said bottom surface with a ram. 
     
     
       4. The method of claim 1 and including the step of applying an adhesive to the side edges of said planar base. 
     
     
       5. The method of claim 1 wherein deflecting said elastic member comprises the step of deflecting said elastic member downwardly so as to invertedly form said cushion. 
     
     
       6. A method for forming a cushion having a smooth bottom surface using a distortable elastic mold capable of being deflected to various depths as needed to properly form the cushion, said cushion comprising a flat planar base, first, second and third resilient blocks, and a resilient cover, said method being performed in the absence of a vacuum, said method comprising the steps of: a) placing said first, second and third resilient blocks on the top surface of said planar base, said second block being of lesser width than said first and third resilient blocks and being sandwiched therebetween;   b) positioning said cover layer atop said resilient blocks with the peripheral portion of said cover layer extending beyond the side edges of said planar base;   c) placing said cover layer, said resilient blocks, and said planar base onto said elastic mold so that the bottom surface of said planar base is exposed;   d) pressing said bottom surface of said planar base to force said cover layer, said resilient blocks, and said planar base into said elastic mold while maintaining a peripheral portion of said bottom surface of said planar base to said side edges exposed;   e) deflecting said elastic mold to a depth to thereby mold said resilient cover layer and said resilient blocks and force said cover layer against the side edges of said planar base as said cover layer is pressed into said elastic mold; and   f) attaching said cover layer to the side edges of said planar base with excess cover layer extending beyond the bottom surface of said planar base to form a seat cushion.